Date: 4th November 2024
Location: Frankfurt/Main Airport, Germany
Aircraft: Airbus A330-900, registration D-ANRC
Flight Number: DE-2369
Operator: Condor Airlines
Flight Route: Phuket (Thailand) to Frankfurt/Main (Germany)
Crew: 2 (no passengers)
Summary of Events
On 4th November 2024, a Condor Airlines Airbus A330-900, performing a positioning flight from Phuket to Frankfurt with no passengers onboard, experienced an engine stall in one of its Rolls-Royce Trent 7000 engines during descent towards Frankfurt. The flight crew shut down the affected engine as a precaution and continued the approach for a safe landing at Frankfurt Airport.
This flight followed an earlier disruption in Phuket, where an abnormal engine indication during taxi-out prevented the aircraft from completing its scheduled passenger flight. After the passengers were disembarked, the aircraft was ferried back to Frankfurt for further inspection and maintenance. The aircraft remains grounded in Frankfurt as of a week after the incident.
Aircraft and Crew Information
The aircraft involved was an Airbus A330-900, part of the A330neo family, known for its fuel efficiency and advanced Rolls-Royce Trent 7000 engines. The specific aircraft, registration D-ANRC, had been in service with Condor Airlines for under three years and was routinely used for long-haul routes.
The crew consisted of two experienced pilots. Their decision to shut down the affected engine and continue on a single-engine landing demonstrated adherence to standard operating procedures and ensured the safety of the flight.
Sequence of Events
1. Preceding Incident in Phuket:
On 3rd November 2024, during taxi-out for a scheduled passenger flight from Phuket to Frankfurt, the aircraft displayed an abnormal engine indication. As a precaution, the crew returned the aircraft to the terminal, and the passengers were disembarked. After troubleshooting, it was determined that the aircraft required further maintenance, prompting the decision to ferry the aircraft back to Frankfurt without passengers.
2. Positioning Flight:
The positioning flight, DE-2369, departed Phuket on 4th November 2024 with only the two flight crew members onboard. The flight proceeded uneventfully until the descent into Frankfurt, when one of the Trent 7000 engines exhibited signs of a stall.
3. Engine Shutdown and Safe Landing:
Upon identifying the engine stall, the flight crew shut down the affected engine in accordance with standard operating procedures. The aircraft continued its descent and performed a single-engine landing at Frankfurt Airport without further incident.
Investigation and Analysis
The investigation into the incident is being conducted by the German Federal Bureau of Aircraft Accident Investigation (BFU), with support from Airbus and Rolls-Royce. The focus of the investigation includes the following areas:
1. Engine Stall and Previous Indications:
The Rolls-Royce Trent 7000 engine had shown abnormal indications during taxi-out in Phuket, prompting the initial cancellation of the passenger flight. The investigation is examining whether the engine stall during descent into Frankfurt is related to the earlier abnormal indications and whether any underlying technical issues contributed to the events.
2. Maintenance and Troubleshooting:
Investigators are reviewing the maintenance records and actions taken in Phuket prior to the positioning flight. This includes an assessment of whether the issue was properly diagnosed and whether the aircraft was safe for the ferry flight.
3. Engine Performance and Design:
The Trent 7000 is a high-bypass turbofan engine designed specifically for the A330neo. The investigation will assess whether the engine stall was due to a design limitation, operational factors, or maintenance oversight.
4. Crew Response:
The flight crew’s response to the engine stall will be evaluated to confirm that appropriate procedures were followed, ensuring a safe outcome. Initial indications suggest the crew handled the situation professionally and effectively.
Key Technical and Operational Factors
• Engine Stall:
An engine stall occurs when airflow through the engine is disrupted, leading to a loss of thrust. Causes can include mechanical issues, sensor malfunctions, or environmental factors such as high-altitude ice crystal ingestion.
• Maintenance History:
The abnormal indication in Phuket and subsequent engine stall during the ferry flight suggest a recurring issue with the affected Trent 7000 engine. Investigators are focusing on whether this was a pre-existing fault or a new issue that developed during the ferry flight.
• Single-Engine Operation:
Modern twin-engine aircraft like the A330-900 are designed to operate safely on a single engine. The flight crew’s actions in shutting down the engine and conducting a single-engine landing are consistent with standard operating procedures for such events.
Conclusions
The engine stall experienced by Condor Flight DE-2369 highlights the importance of proactive troubleshooting and maintenance in addressing abnormal engine indications. While the flight crew’s actions ensured a safe landing, the recurrence of engine issues raises questions about the reliability of the affected engine and the adequacy of diagnostic procedures.
The aircraft’s grounding at Frankfurt for over a week underscores the complexity of resolving the underlying technical issue and ensuring the long-term safety and reliability of the engine.
Recommendations
1. Comprehensive Engine Inspections:
Rolls-Royce and Condor Airlines should conduct a detailed examination of the affected Trent 7000 engine to identify the root cause of the stall and abnormal indications.
2. Enhanced Troubleshooting Protocols:
Maintenance teams should review and, if necessary, update troubleshooting protocols to ensure that recurring issues are addressed comprehensively before an aircraft is cleared for further flights.
3. Monitoring of Trent 7000 Fleet:
Airlines operating A330-900 aircraft with Trent 7000 engines should increase monitoring for similar indications, implementing additional inspections if required.
4. Pilot Training for Engine Malfunctions:
Airlines should continue to emphasize single-engine operation training for flight crews, ensuring familiarity with handling engine stalls and shutdowns during flight.
5. Review of Maintenance and Operational Decisions:
The decision to ferry the aircraft back to Frankfurt will be reviewed to ensure that all safety considerations were appropriately weighed against operational pressures.
Safety Lessons and Industry Impact
This investigation underscores the importance of rigorous maintenance and diagnostics for advanced aircraft engines. The incident serves as a reminder of the challenges associated with troubleshooting and resolving issues in complex systems like the Trent 7000, especially in operational settings.
As investigations proceed, the findings are likely to influence maintenance protocols and operational practices for airlines operating the A330neo and similar aircraft. Enhanced collaboration between manufacturers, operators, and regulators will be key to ensuring the continued safety of these advanced aircraft.
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